Dual ratio master cylinder

ABSTRACT

A DUAL RATIO MASTER CYLINDER ADAPTED TO BE CONNECTED TO A HYDRAULIC BRAKING SYSTEM, THE MASTER CYLINDER INCLUDING A PAIR OF PISTONS OF DIFFERENT DIAMETER OPERABLE WITHIN A BORE AND MEANS DISPOSED BETWEEN THE PISTON ADAPTED TO EXERT A FORCE TO RESIST A COMPRESSIVE FORCE UP TO A PREDETERMINED VALUE SUCH THAT UPON ACTIVATION OF THE MASTER CYLINDER, ALL &#34;PLAY&#34; IN THE SYSTEM IS REMOVED IN A LOW PRESSURE HIGH VOLUME OPERATION UNTIL A PREDETERMINED PRESSURE IS BUILT UP WITHIN THE SYSTEM AT WHICH TIME A SECONDARY HYDRAULIC BOOSTER ACTS TO BUILD UP ADDITIONAL PRESSURE IN A HIGHER PRESSURE LOWER VOLUME PHASE OF OPERATION.

Feb. 9, 1971 SHEER 3,561,213

DUAL RATIO MASTER CYLINDER Filed June 27, 1969 10 12 17. s1'3s1511 a 37 23 18 48 52 2 1 do 41 a z'e 2'5 31 United States Patent Oifice Patented Feb. 9, 1971 US. Cl. 60-54.5 12 Claims ABSTRACT OF THE DISCLOSURE A dual ratio master cylinder adapted to be connected to a hydraulic braking system, the master cylinder including a pair of pistons of different diameter operable within a bore and means dsiposed between the pistons adapted to exert a force to resist a compressive force up to a predetermined value such that upon activation of the master cylinder, all play in the system is removed in a low pressure high volume operation until a predetermined pressure is built up within the system at which time a secondary hydraulic booster acts to build up additional pressure in a higher pressure lower volume phase of operation.

SUMMARY OF THE INVENTION This invention relates to hydraulic master cylinders and more particularly, to hydraulic master cylinders of the dual ratio type. Dual ratio master cylinders have been known in the brake art for some time. The main purpose for such a device is to bridge the gap presently existing in the market between brake systems of the power assist type and manual braking systems with no assist. The aim of such systems is to provide a brake master cylinder that will require less pedal effort with the same foot travel as existing manual master cylinders and to supply lower pedal effort to power assisted systems when the power assist is inoperative.

The optimum design for any braking system is to generate the maximum line pressure while utilizing the minimum pedal force and the smallest pedal travel. In manual systems presently in existence, any efforts to decrease pedal effort to generate the same line pressure result in an increase in pedal travel and any efforts tending to decrease pedal travel result in an increase in the pedal force which must be applied.

The purpose of a dual ratio master cylinder is to generate line pressure in two stages. Stage one utilizes movement of a large area piston to displace a large volume of fluid at low pressure with minimum pedal travel. This stage will function to take up all slack in the system, and set the brake shoes against the drums in drum brake systems or the pads against the discs in a disc brake system and build up line pressure to a predetermined value.

At this point, termed the transition point, the second stage will become operative utilizing a smaller area piston to displace a smaller volume of fluid to build up additional pressure and apply the brakes.

Previous designs of this type have included serious shortcomings which caused the automotive industry to reject them except for industrial applications where they are presently in use. Certain of these shortcomings included:

(l) The transition point could be detected at the brake pedal resulting in an unsatisfactory feel to the operators foot.

(2) The unit switched to the second stage at a geometrically predetermined point which caused brake application during the first stage when brakes were adjusted tight, or excessive pedal travel when brakes were loose.

(3) Many of the units had no fail safe switch-back feature whereby the device could return from second stage application to first stage application if either the brake system or master cylinder developed a leak under pressure.

Due to these shortcomings, efforts to introduce this type of unit to wide use have, so far, been fruitless.

The present invention is directed to providing a dual ratio master cylinder utilizing a high ratio in the master cylinder for initial pressure generation to remove play in the system and to set the brake shoes against the drums. The second stage of operation employs a hydraulic booster of lower ratio which builds up additional pressure. The present invention further provides a fail-safe backup device which will cause the master cylinder to revert to the high ratio stage to deliver pressure to the hydraulic brake system, if the secondary system becomes inoperative after a certain degree of travel.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a sectional view showing an embodiment of the invention with the movable parts of the structure positioned normally before operation of the brakes.

FIG. 2 is a sectional view showing the parts related after initial operation of the brake pedal in the low pressure high volume stage.

FIG. 3 is a sectional view showing the parts related in the high pressure low volume stage.

FIG. 4 is a sectional view showing the parts reverting back to the initial stage of operation.

FIG. 5 is a sectional view of a tandem master cylinder incorporating the features of the present invention.

FIG. 6 is a sectional view of a modified embodiment of the invention. 1

DESCRIPTION OF THE PREFERRED EMBODIMENT As best illustrated in FIG. 1, a dual ratio master cylinder 10 is shown including a housing generally identified as 11. A fluid reservoir 12 is shown defined by the housing 11. Also defined by the housing 11 is a stepped bore 14. The bore 14 includes a relatively large diameter portion 13 and a relatively small diameter portion 15. In one end of the bore 14 is a fluid outlet 16 here shown as a conventional residual pressure valve and is adapted to be connected to a hydraulic braking system (not shown). A fluid conduit 17 and a port 18 connect the fluid reservoir 12 to portion 13 of the bore 14.

A hollow piston 20 is shown slidably disposed in the large diameter portion 13 of bore 14 and is adapted to slide axially along said portion. The piston 20 is operative to divide the bore 14 of housing 11 into a low pressure chamber A and a high pressure chamber B which will be more fully described later. The piston 20 defines an internal bore 21. A fluid conduit 22 is shown defined by the piston 20 and includes an inlet port 24. The piston 20' includes a pair of land sections 23 and 25, and a peripheral relief 26. A seal 27 is shown disposed intermediate the land section 23 and portion 13 of the bore 14. A lip seal 28 is shown connected to an end face 30 of the piston 20. A resilient member, here shown as a coil spring 31, is disposed between the lip seal 28 and the fluid outlet 16 and is adapted to urge the piston 20 to the left as shown in FIG. 1.

A piston 32 is shown disposed in the small diameter portion 15 of bore 14, the piston having an outer diameter smaller than the outer diameter of the piston 20, but larger than the inner diameter of the bore 21. The piston 32 defines an inner bore 33 having an end wall 35.

The high pressure chamber previously referred to will now be defined as the variable volume which exists in section 13 between the lip seal 28 after it has closed off port 18 and the fluid outlet 16. The low pressure chamber A will be defined as the variable volume existing in the face 14 between end wall 35 of piston 32 and the inlet port 24 of conduit 22.

A mechanical linkage 36 is connected between the piston 32 and the piston 20 to urge them to a predetermined relative axial displacement. The mechanical linkage 36 includes an axially extending rod 37 which is connected to the piston 32. On one end of the rod 37 is an enlarged head 38. A sleeve 40 is shown defining a hollow cavity 41. The sleeve 40 includes an annular upturned shoulder 42. An apertured washer 43 is connected to the piston 20 and serves to limit the movement of the sleeve 40 to the left by its contact with the shoulder 42. The apertured washer 43 permits flow between the reservoir 12 and the chamber A. Inserted in one end of the cavity 41 is a valve member 44 which is adapted to seat against inlet port 24. The sleeve 40 defines an opening 45 in the other end through which the connecting rod 37 extends. A resilient member 46, here shown as a coil spring, is positioned between the piston 32 and the sleeve 40 to urge them apart.

Means 48 are provided disposed between the piston 20 and the piston 32 which are adapted to resist any compressive force urging the pistons together. This means 48 is further adapted to maintain a predetermined distance between the pistons up to a predetermined value of said compressive force, the means being yieldable above the predetermined value to allow relative movement between the pistons, the separating force remaining substantially constant. The means 48 is shown here as a preloaded conventional compression coil spring. It should be realized, however, that any of a number of other above the predetermined value to allow relative movement means functioning in the same manner could replace the compression spring 48 without substantially altering the principles of the present invention.

The piston 32 defines a concave surface 51 in one end thereof which is adapted to receive push rod 53 which is connected to a brake linkage assembly not shown. The push rod 53 is held in position by a snap ring 52. A seal 55 is disposed in the outer periphery of the piston 32 between the piston 32 and the bore 14.

The operation of the embodiment shown in FIGS. 1 through 4 is as follows. When energization of the hydraulic brake system is desired, force is applied to the brake pedal (not shown) which, through the brake linkage, transmits the force to the push rod 53. The push rod 53 moves to the right as shown in FIG. 1 urging piston 32 to the right also. At this point, there is relatively little pressure in the brake lines to act against the lip seal 28. The compression spring 48 acts to maintain the predetermined axial distance between pistons 20 and 32. The mechanical linkage 36 urges the pistons 20 and 32 to a predetermined relative axial displacement.

Any slight movement of piston 20 to the right as shown in FIG. 2 will cause the lip seal 28 to pass over the port 18 thereby isolating the pressure chamber B and the rest of the hydraulic brake system from the fluid reservoir 12. As a result of such isolation, pressure is now built up in the brake lines and the brake shoes expand to contact the respective brake drums.

As the push rod 53 is forced further to the right, as shown in FIG. 2, and correspondingly the pistons move further to the right, all play in the system is removed at a high ratio due to the relatively large area of the piston 20 and, correspondingly, a relatively large volume of fluid is displaced due to movement of the piston 20. When the play is removed as the piston 20 moves further to the right, the pressure in the system increases.

At this point, it should be obvious that a compressive force is exerted on the resilient means 48 tending to collapse such resilient means and to allow for relative movement between the pistons 20 and 32, to bring them closer together. The compressive force is due to a combination of forces neglecting the effects of friction. One such force acts to the left against lip seal 28 and is generated by the pressure built up in the hydraulic brake system acting against the area of the end face of the piston 20. The other force contributing to the compression of the resilient means 48 is the force applied by the push rod 53 to the piston 32 at its left nd. The resilient means 48 will allow no relative movement between the pistons until the compressive force is suflicient to overcome the design pre-load force of the spring member 48.

Since no relative movement between the pistons has taken place, the valve member 44 remains off conduit 22 allowing commuication between the fluid reservoir 12 and the inner bore 21 of piston 20 through the apertured washer 43. As the piston 20 moves to the right as shown in FIG. 2, a vacuum is created behind the piston in the section 13. Hydraulic fluid is caused to flow from the fluid reservoir 12 through the conduit 17, through peripherial relief 26, through conduit 22, inlet port 24 and through apertured washer 43 to fill this expanding volume.

As soon as the pressure in the hydraulic braking system has reached a predetermined point, suflicient such that the pressure times the area of end face 30 of piston 20 produces a force which in combination with the force exerted by push rod 53 will overcome the pre-load force inherent in resilient means 48, the spring force will be overcome thus allowing relative movement between pistons 20 and 32. Still, resilient means 48 will exert a separating force on pistons 20 and 32 which is substantially constant.

For a short interval, piston 20 will remain stationary while piston 32 moves toward it. The mechanical linkage 36 urges the sleeve and the valve member 44 to the right such that the valve member 44 will seat upon inlet port 24 of conduit 22, thereby blocking any fluid flow between the fluid reservoir 12 and the low-pressure chamber. The fluid contained in the low-pressure chamber comprised of inner bore 21, inner bore 33 and the area behind the piston member 20 in section 13 is now trapped.

At this point, the operation of the master cylinder is now in the second stage as best shown in FIG. 3. Since the fluid is trapped, any movement of piston 32 toward piston 20 will result in a proportional movement of the piston 20 since the trapped fluid is substantially noncompressible. Due to the diflerence in areas between piston 20 and piston 32, and accordingly, the difference in volumes displaced by movements of the pistons, movement of the piston 32 for any given distance will result in movement of the piston 20 through a lesser distance. The distances moved by the pistons are reciprocal to the areas of the pistons. For instance, if the area of piston 20 is three times the area of piston 32, any movement of piston 32 for three-tenths of an inch, will result in a corresponding movement of piston 20 of one-tenth of an inch. Movement of the piston 20 creates additional pressure in the hydraulic brake system in addition to pressure reached in first stage and acts to apply the brakes.

If any leak under pressure would develop in prior art devices in the hydraulic brake system which would require displacement of a large volume of fluid to apply the brakes, such pressure would be generated in the high pressure low volume stage requiring excessive pedal travel. To preclude such results, a safety feature is incorporated in the operation of the present invention as best shown in FIG. 4 which will establish a mechanical connection between the pistons 20 and 32 atfer a pre determined amount of relative movement therebetween. The outer diameter of piston 32 is greater than the inner diameter of the bore 21 defined in piston 20. After a given movement between the pistons, the outer diameter of piston member 32 will come into abutting relationship with the piston member 20 and in eltect, the unit will operate as a solid assembly thereby switching back to the first stage of operation wherein any motion of the push rod 53 will result in a corresponding motion of the piston 20 which, in eifect, is the same as the operation in the first stage.

When pressure is released on the brake pedal, the force of the resilient means 48 positioned between the pistons 20 and 32 will act to move the pistons axially away from each other. The spring 31 will act to return piston 20 to the left. As the pistons 20 and 32 move relatively away from each other, the piston 38 engages one end of the sleeve 40 and moves to the left which will act to move the valve member 44 olf the conduit 22 thereby re-establishing contact between the fluid reservoir 12 and the inner bore 21.

FIG. shows a tandem master cylinder 60 incorporating the features of the present invention. The operation of this device is for all practical purposes, identical to the operation of the device shown and described in FIGS. -1 through 4. Structurally, the only main difference is the incorporation of two fluid reservoirs 61 and 62 separated one from another and defined in the housing 11 of the master cylinder 60. A pair of fluid outlets 63 and 65 are shown in communication with the bore 13. Each outlet is adapted to be connected to a hydraulic line leading to a pair of wheel brakes. An additional piston member 66 is shown slidably disposed within the bore 13 and the piston member includes a pair of lip seals 67 and 68, each being attached to an end of the piston 66. Conduits 70 and 70' and ports 71 and 71 are shown connecting each of the respective fluid reservoirs 61 and 62 to the bore 13.

FIG. 6 shows a modified embodiment of a master cylinder 75 incorporating the features of the present invention. The master cylinder 75 includes a housing generally identified a 76. A fluid reservoir 77 is shown defined by the housing 76. Also defined by the housing 76 is a bore 78. In one end of the bore 78 is a fluid outlet 80 which is adapted to be connected to the hydraulic braking system. A fluid conduit '81 is shown connecting the fluid reservoir 77 to the bore 78. A port 82 is shown connecting the fluid reservoir 77 to the bore 78.

A hollow piston 83 is shown slidably disposed in the bore 78 adapted to slide axially along said bore. The piston 83 defines an internal bore 85. The piston 83 further defines a plurality of ports 86 which forms a part of a fluid circuit between the reservoir 77 and the internal bore 85. A lip seal 87 is shown connected to the piston 83 at one end.

A second piston '88 is shown operative within the bore 78 and slidably disposed within the internal bore 85 of the piston 83. The piston 88 includes a tubular shaft 89 which is adapted to be connected to the brake pedal linkage. The shaft 89 defines an inner bore 90 and a plurality of ports 91.

Means 83 are provided disposed between the piston 83 and the piston 88 which are adapted to resist any compressive force urging the pistons together. This means 93 is further adapted to maintain a predetermined distance between the pistons up to a predetermined value of said compressive force, the means being yieldable above the predetermined value to allow relative movement between the pistons, the separating force remaining substantially constant. The means 93 is shown here as a pre-loaded conventional compression coil spring.

The operation of the embodiment shown in FIG. 6 is substantially the same as the operation of the embodiment shown in FIGS. 1 through 4. When shaft 89 is moved to the right by its connection with the brake pedal, the pre-lo ad spring 93 will move the piston 83 also. As soon as the piston 83 passes the port 82, the fluid outlet 80 and the rest of the hydraulic brake system are isolated from the fluid reservoir 77. As the piston 83 moves to the right, fluid is forced from the outlet and pressure is built up in the system.

At the same time the piston 83 is moving to the right, hydraulic fluid is drawn through the port 81 and the port 86 to fill the expanding volume behind the piston 83.

When the slack has been taken out of the braking system and the pressure in the system increases to a value sufficient to generate a force greater than the pre load force of the spring 93, the spring will be overcome and the piston 88 will slide within bore axially toward the piston 83. When the piston 88 passes the ports 86, the fluid contained in the fluid chamber defined between the pistons 83 and 88 is trapped. As the piston 88 continues to slide within the bore 85, fluid is forced through the ports 91 and acts against the back face of the piston 83. Since the effective area of the piston 88 is smaller than the eflective area of the piston 83, a ratio relationship will exist.

If, for any reason, a leak would develop in the system requiring displacement of a large volume of fluid to apply the brakes, the piston 88 would bottom against the piston 83 establishing a mechanical connection between the pistons after a predetermined amount of relative movement therebetween.

Various of the features of the invention have been particularly shown and described, however, it should be obvious to one skilled in the art that various modifications may be made therein without departing from the scope of the invention.

What is claimed is:

1. A pressure cylinder for a hydraulic brake system including a housing; a bore defined by said housing; a fluid reservoir in communication with said bore; a fluid outlet associated with said bore adapted to be connected to said hydraulic brake system; a pair of pistons operable within said bore; a fluid chamber defined by said pistons and said bore; a fluid circuit adapted to communicate fluid between said fluid reservoir and said fluid chamber; means disposed between said pistons adapted to exert a force to resist a compressive force urging said pistons together and to maintain a predetermined distance between said pistons up to a predetermined value of said compressive force, said means being yieldable above said predetermined value to allow relative movement of said pistons toward one another, said force resisting said compressive force remaining substantially constant and valve means associated with one of said pistons operative upon yielding of said means between said pistons to close said fluid circuit between said reservoir and said fluid chamber.

2. A pressure cylinder as in claim 1 in which said means disposed between said pistons is a preloaded spring device adapted to be compressed only after said preload is overcome.

3. A pressure cylinder as in claim 1 including a fluid passage in said fluid circuit defined by one of said pistons, said fluid passage adapted to communicate fluid from said fluid reservoir to said fluid chamber.

4. A pressure cylinder as in claim 1 including means to establish a mechanical connection between said first and second pistons after a predetermined amount of relative movement therebetween.

5. A pressure cylinder as in claim 1 in which one of said pistons defines an internal bore and the other of said pistons is slidably disposed within said internal bore.

6. A pressure cylinder for a hydraulic brake system including a housing; a bore defined by said housing; a fluid reservoir in communication with said bore; a first piston slidable within said bore adapted to divide said bore into a pair of pressure chambers including a low pressure chamber and a high pressure chamber; a second piston cooperative with said first piston to define said low pressure chamber; a fluid circuit adapted to communicate fluid between said fluid reservoir and said low pressure chamber; a fluid outlet associated with said high pressure chamber adapted to connect said high pressure chamber to said hydraulic brake system; means disposed between said pistons adapted to resist a compressive force urging said pistons together, said means being yieldable above said predetermined value to allow relative movement of said pistons toward one another, said force resisting said compressive force remaining substantially constant and valve means associated with one of said pistons operative upon yielding of said means between said pistons to close said fluid circuit between said reservoir and said low pressure chamber.

7. A pressure cylinder as in claim '6 in which said means disposed between said pistons is a preloaded spring device adapted to be compressed only after said preload is overcome.

8. A pressure cylinder as in claim 6 including a fluid passage in said fluid circuit defined by said first piston adapted to communicate fluid from said fluid reservoir to said low pressure chamber.

9. A pressure cylinder as in claim 6 including means to establish a mechanical connection between said first and second pistons after a predetermined amount of relative movement therebetween.

10. A pressure cylinder as in claim 6 in which one of said pistons defines an internal bore and the other of said pistons is slidably disposed Within said internal bore.

11. A pressure cylinder for hydraulic brakes including a housing; a bore defined by said housing; a pair of fluid reservoirs, each of said reservoirs in communication with said bore; a pair of fluid outlets in communication with said bore adapted to be connected to a hydraulic braking system; a pair of pistons operable within said bore; a third piston slidably disposed in said bore and positioned between said fluid outlets; means disposed between said pair of pistons adapted to exert a force to resist any compressive force urging said pistons together and to maintain a predetermined axial distance between said pistons up to a predetermined value of said compressive force, said means being yieldable above said predetermined value to allow relative movement of said pistons toward one another, said force resisting said compressive force remaining substantially constant.

12. A pressure cylinder for a hydraulic brake system including a housing; a stepped bore defined by said housing including a relatively large diameter portion and a relatively small diameter portion; a fluid reservoir in communication with said bore; a fluid outlet associated with said bore adapted to be connected to said hydraulic brake system; a first piston slidable within said relatively large diameter bore, said first piston defining an inner bore; a second piston slidably disposed within said inner bore of said first piston; a fluid chamber defined by said pistons and said bore; a fluid circuit adapted to communicate fluid between said fluid reservoir and said fluid chamber; means disposed between said pistons adapted to exert a force to resist a compressive force urging said pistons together and to maintain a predetermined distance between said pistons up to a predetermined value of said compressive force, said means being yieldable above said predetermined value to allow relative movement of said second piston toward said first piston, said force resisting said compressive force remaining substantially constant and valve means associated with one of said pistons operative upon yielding of said means between said pistons to close said fluid circuit between said reservoir and said chamber.

References Cited UNITED STATES PATENTS 2,179,241 11/1939 Groves 54.6A 2,313,273 3/ 1943 Schnell 6054.6A 2,313,274 3/1943 Schnell 60-54.6A 2,343,900 3/ 1944 Groves 6054.6A 2,343,901 3/1944 Groves 6054.6A 2,407,957 9/ 1946 Hull-Ryde 60-54.6A 2,820,347 1/1958 Highland et al. 6054.6A 2,886,950 5/1959 Hause 60-54.6P 3,191,384 6/1965 Krusemark 60--54.6A 3,478,518 11/1969 Lagerquist 60-54.6A

MARTIN P. SCHWADRON, Primary Examiner R. R. BUNEVICH, Assistant Examiner US. Cl. X.R. 6054.6

Dedication 3,561,213.Samuel Shiber, Chicago, Ill. DUAL RATIO MASTER CYLIN- DER. Patent dated Feb. 9, 1971. Dedication filed Jan. 21, 1972, by the assignee, Borg-Warner Corporation. Hereby dedicates t0 the People of the United States the entire remaining term of said atent.

[0 cz'al Gazette A m'l J], 19732.] 

